Nonwoven Fabric Sheet And Method For Making The Same

A patterned spunbonded nonwoven fabric sheet comprising a plurality of spunbonded crimped fibers bonded together at a plurality of bonding points, wherein all fibers of the patterned spunbonded nonwoven fabric sheet are spunbonded crimped fibers,

• characterized in that
• the density of fibers, or the mean orientation of the fibers, or the mean crimp radius of the fibers within the fabric sheet, or any combination thereof, are inhomogeneous and varies according to a regular pattern wherein the sheet has a three-dimensional structure comprising a plurality of alternating elevations and depressions arranged according to the pattern.

A flat spunbonded nonwoven fabric sheet starting material comprising a plurality of spunbonded crimped fibers, wherein the nonwoven is obtained by a process that involves a step of heat embossing with a calender roll to bond together the fibers at a plurality of bonding points, wherein all fibers of the flat spunbonded nonwoven fabric sheet are spunbonded crimped fibers, wherein the number of bonding points per cm2 of fabric surface is between 10 and 40, and wherein the total area of bonding points is between 6 and 18% of the total area of the fabric,

• characterized in that
• the quotient obtained by dividing the basis weight of the fabric sheet, as expressed in grams per square meter (g/m2), with the height of the embossing pins on the calender roll, as expressed in millimeters (mm), is between 20 and 150.